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24-38CXI Range Installation & Service Manual Boilers - Glow-worm

1. Ball valves are fitted in water and gas connections DOMESTIC CIRCUIT PMW 10 bar HEATING CIRCUIT PMS 3bar 87 0 41 For larger systems use an additional INJECTOR N A DOES NOT APPLY i DHW CH MAX MAX MIN HEAT INPUT NETTQ kw 38 42 30 15 6 7 HEAT OUTPUTP kW 3822 30 0 6 62 SERIAL No Diagram 1 2 11 0020013349 02 1 Technical Information Certification This boiler certificated to the current issue of EN 483 2000 for performance and safety It is important that no alteration is made to the boiler without permission in writing from Glow worm Any alteration that is not approved by Glow worm could invalidate the warranty and could also infringe the current issue of the Statutory Requirements 1 3 Gas Supply The gas installation must be in accordance with the relevant standards In GB this is BS6891 In IE this is the current edition of 1 5 813 Domestic Gas Installations The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler On completion test the gas installation for soundness using the pressure drop method and suitable leak detection fluid purge in accordance with the above standard 1 4 Technical Data All dimensions are given in millimetres except as noted See diagrams 1 1 and Tables 1 and 2 The data label is positioned on the inner door refer to diagram 1 2
2. NOTE When reconnecting electrical connections polarity is not important Carry out a functional test of the controls 14 18 Heating Flow Thermistor For access refer to section 14 1 Refer to diagram 14 15 Remove the electrical connections from the thermistor Remove the retaining clip from the flow pipe NOTE When reconnecting thermistors is not mportant the polarity of the wiring to 14 19 Heating Return Thermistor For access refer to section 14 1 Refer to diagram 14 15 Remove the electrical connections from the thermistor Remove the retaining clip from the return pipe NOTE When reconnecting the polarity of the wiring to thermistors is not important 14 20 Overheat Thermostat For access refer to section 14 1 Refer to diagram 14 15 Remove the electrical connections from the overheat thermostat Remove the retaining clip from the flow pipe Remove the overheat thermostat from the retaining clip NOTE When fitting new thermostat please ensure that it is located correctly onto the flat area of the pipe and the retaining clip is secure 14 21 Automatic Air Vent For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Refer to diagram 14 16 Unscrew the automatic air vent Fit the new automatic air vent and O ring ensuring the vent cap is left loose Refill vent and pressurise the boiler Check for leaks 0020013349 02 44 DOMESTIC HOT WA
3. Instruct and demonstrate the lighting procedure and advise the user on the safe and efficient operation of the boiler Instruct on and demonstrate the operation of any heating system controls Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK The user shall not interfere with or adjust sealed components It is the Law that any servicing is carried out by a competent person Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler Advise the user of the precautions necessary to prevent damage to the system boiler and the building in the event of the heating system being out of use during frost or freezing conditions Advise the user that the permanent mains electrical supply SHOULD NOT be switched off
4. Take the wall template from the documentation pack and place in the desired position on a flat wall giving due consideration to boiler clearances see section 2 and the flue you are fitting 6 3 Flue Hole Cutting The standard horizontal flue is designed with an internal fall of 44mm metre towards the boiler for disposal of condensate If the standard flue length alone is being used then the flue hole of diameter 105mm can be cut in the position marked on the wall template For standard side flues the horizontal flue centre line on the wall template should be extended to the side wall and the vertical centre of the flue hole marked at 176mm from the back wall For installations with external access a 105mm diameter core drill can be used For installations with internal access only a 125mm diameter core drill should be used When using extension pipes with the horizontal rear flue a core drill size of 125mm should be used to allow the extension pieces to slope at 44mm metre 2 5 towards the boiler For extended side flues the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall This dashed line is drawn at 44mm metre 2 5 rise from the boiler Where this line reaches the side wall a horizontal line should be marked The vertical centre line of the flue should then be marked at 176mm from the back wall see diagram 6 2 To allow for the flue passing through the w
5. reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Avoid upper body top heavy bending do notlean forward sideways Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation within compartment etc restricting installation Recommend 2 persons lift appliance to position into place space permitting Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at frontand sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance
6. BOILER COLLAR OUTSIDE WALL FACE MOUNTING WALL DRILL AND SCREW Diagram 9 4 Top Side flue Telescopic with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 9 6 If the measurement Y exceeds 525mm then the appropriate length of extension pipe is required if the dimension is less than 320mm DO NOT cut the flue it can project to a maximum of 600mm if this is not desirable then a Standard flue MUST be used and cut to length 9 Y co N OUTER FLUE RUBBER DUCT AIR COLLAR COLLAR DUCT DRILL AND SCREW OUTSIDE WALL FACE INNER PLASTIC COLLAR TOP SIDE FLUE STANDARD Diagram 9 5 Y 8 OUTER FLUE gt RUBBER DUCT AIR COLLAR DUCT COLLAR DRILL AND SCREW OUTSIDE WALL FACE INNER PLASTIC COLLAR TOP SIDE FLUE TELESCOPIC Diagram 9 6 25 0020013349 02 9 Flue Preparation Telescopic and Standard Flue 9 2 cont d Flue and Air Ducts Telescopic The Telescopic Flue system MUST NOT be cut Adjust the flue to your required length Y mark the securing hole position in the air duct Drill a 3mm diameter hole at this position take care not to pierce the inner flue duct Secure with screw provided and tape the joint see diagram 9 7 Standard Separate the flue duct from the terminal by twisting to release the terminal catch then pull out of the retaining seal refer
7. Positioning of Appliance for Final Installation in roof space restricting installation Recommend 2 persons lift appliance to position into place space permitting Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance It is recommended a risk assessmentofthe roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Appliance Safety Devices User Instructions Electrical Supply Failure Reset Switch The boiler will not work without an electrical supply Normal operatio
8. The Seasonal Efficiency Domestic Boilers UK SEDBUK is Class A 24cxi 90 396 30cxi 90 3 amp 38cxi 90 6 Thevalueisusedinthe UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated has been certified by B S I 1 5 Condensate Drain A plastic drain pipe must be fitted to allow discharge of condensate to a drain Condensate should if possible be discharged into the internal household draining system If this is not practical discharge can be made externally into the household drainage system or a purpose designed soak away see section 8 2 for more details 1 6 Upward Piping Kits Wherethe domestic hot water and heating flow and return pipes come from above the boiler or just the heating flow and return pipes upward piping kits are available to facilitate this Central Heating only part No A2051000 Central Heating and DHW part No A2050900 Contact Glow worm for further details 1 7 Optional Programmer Kit An optional programmer for fitting in the boiler is available Pt no A20087 electromechanical or A20087 digital 002001 3349 02 HEAT EXCHANGER Et o BURNER FLOW THERMISTOR EXPANSION VESSEL OVERHEAT CUT OFF RETURN THERMISTOR GAS CONTROL VALVE FAN AUTOMATIC PUMP PLATETO PLATE SYSTEM HEAT PRESSURE DIVERTER EXCHANGER VALVE MOTOR WW FLOW SENSOR SAFETY DISCHA
9. NO Is there temperature indicated on LCD Is F displayed YES Check wires between main pcb and interface Does appliance fire YES Does boiler modulate before desired set point is reached REFER TO F CODE POSSIBLE CAUSES 21 DIAGRAM 13 3 Differential is too high Current flow rate too low NO Does boiler go off YES T emperature rise too high before desired set point Asin flow rate too pn is reached NO Are radiators getting warm rrr F 9 Check operation of 3 way valve YES Normal operation Turn a hot tap on Does the LCD change to display pressure YES Does the boiler produce hot water YES NO Faulty flow sensor COMPONENT CH thermistor 10K Q 25 C Fan 24V DC across blue and red at fan Gas Valve 24V DC 55 Q Flow sensor Remove and check rotation of paddle wheel 3 Way valve Remove motor switch tap on and off and check spindle moves in and out Normal operation Diagram 13 2 002001 3349 02 38 13 Fault Finding DESCRIPTION POSSIBLE CAUSE Ignition fault lockout Boiler failed to light No gas Insufficient gas Incorrect gas valve adjustment Electrode Ignition lead defect Electronic igniter defective Check air inlet duct Check connections to igniter unit 12352 Ignition fault lockout Went out when lit As F1 possible cause Overheat fault Overhe
10. RET 20 02kW Safety valve discharge 15mm copper DAW CH i MAX MAX MIN Expansion vessel capacity 8 litres 1 76 gallons we A PU 1531 a Charge pressure O 5bar 7 3lbf in SERIAL No J Heating system 0 7bar 10 11bf in minimum pressure C Slow worm 2000460371 D H W Max working pressure 10bar 1451Ibf in2 BELPER DERBYSHIRE DE56 1JT Minimum working pressure for Pa RO SOW ted ot max domestic flow rate 0 2bar 2 9Ibf ir 0 4 For use on IL TYPE Cis Cos Ces Cd Max Domestig hot water flow rate f f Adjusted for use on EN437 IP X4D at 35 C rise 24 cxi 9 8L min natural gas 620 20 mbar NOx Class 5 30 oxi 12 3L min This boiler is intended exclusively n to be installed on a gas supply 38 cxi 15 5L min with a governed meter Min Domestic hot water flow rate 24 30 38 1L min Maximum flow temperature 63 C m Maximum heating system 130 litres water content using 28 6 gallons pressurised at 1bar fitted expansion vessel oe kW at 75 C average system temperature C Slow worm 2000460559 Electrical supply 230V 50Hz DERBYSHIRE DESAI Electrical rating 180W fused 3A 38cxi HIGH EFFICIENCY CONDENSING COMBI BOILER IP classification X4D 230V 50Hz 180W Fused at GC No 47 047 27 Internal Fuse rating For use on I 2 G20 20 mbar 1613633453 On PCB 630mAT This boiler is intended exclusively ENAS IP X40 NOx Class 5 to be installed on a gas supply ith t
11. 2 must not be modified or blocked Pluming from flue terminal Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler It is normal and not a fault indication Cleaning The boiler casing can be cleaned using a mild liquid detergent with a damp cloth then a dry cloth to polish Do not use any form of abrasive or solvent cleaner as you may damage the paintwork Electrical Supply If the mains electricity and gas are to be turned off for any long periods during severe weather it is recommended that the whole system including the boiler should be drained to avoid the risk of freezing Make sure that if fitted the immersion heater in the cylinder is switched off NOTE If you have a sealed water system contact your installation servicing company as draining refilling and pressurising MUST be carried out by a competent person Manual Handling IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift General recommendations when handling Clear the route before attempting the lift Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Do not twist reposition feet instead If 2 persons performin
12. Close the hot water tap and check for any leaks 12 11 Inner Casing Panel Seal Check Check the condition of the seal replace as required To replace remove the old seal thoroughly clean the casing sufaces Fitthe new seal itis supplied to the correct length see diagram 12 11 35 mb CLIP 12771 moe CENTRAL HEATING RETURN FILTER 12773 GAS SERVICE COCK Diagram 12 10 FRONT 9 CASING S PANEL INNER CASING PANEL Diagram 12 11 0020013349 02 13 Fault Finding NOTE Before trying to operate the boiler make sure that All gas supply cocks are open and that the gas supply has been purged of air There is a permanent mains supply to the boiler There is a heating demand from the external controls WARNING Always isolate the boiler from the electrical supply before carrying out any electrical replacement work Always check for gas soundness after any service work Electrical Testing Shouldthere be any doubt aboutthe voltage supply to any ofthe components it is possible to carry out a simple electrical test Important On completion of the Service Fault Finding tasks which have required the breaking and remaking ofthe electrical connections the earth continuity polarity short circuit and resistance to earth checks must be repeated using a suitable multimeter To carry out the electrical test gain a
13. Mode Normal mode uses the domestic hot water and central heating temperatures selected By turning the central heating water temperature and hot water temperature control knobs to minimum setting the holiday mode is set up However frost protection and pump exercise programme remain active By doing this the DHW will operate without pre heat and DHW will set at maximum temperature To resume normal operation after a holiday period return the control knobs to their original position 11 9 Pump Exercise Program After a power cut or every 24 hours in holiday mode the three way valve will switch and the pump will run to prevent the components from sticking This will also occur during normal operating if there is no domestic or central heating demand for more than 24 hours 11 10 Frost Protection The boiler has a built in frost protection programme as long as the electricity and gas are left switched on This device operates the appliance pump when the temperature inside the boiler falls below 7 C and circulates water around the appliance only If the temperature falls to 3 C the burner is lit and water circulates around the heating system When the temperature inside the appliance reaches 10 C the burner will shut down and after a short period the pump will stop This device primarily protects the boiler Any other exposed areas of the system should be protected by a separate frost thermostat 31 11 11 Instruct the User
14. PCB i BOILER cONTRoLs CONNECTOR J15 A INTERFACE PCB VOLTAGE FREE HEATING CONTROLS CONNECTION ON CONTROLS BOX COVER DOUBLE POLE ISOLATOR E PROGRAMMER B VOLTAGE FREE 230 50Hz ROOM THERMOSTAT r Diagram 10 2 0020013349 02 10 Electrical Connection 10 3 Mains Voltage System Controls WARNING UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TOANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG Remove the MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG from the fittings pack and install on the control interface PCB as follows Gain access to the control and user interface PCB s by unclipping the fascia panel and hinging forward see diagram 10 3 Route the system controls cable and connect to the plug see diagram 10 3 Insert plug onto controls interface PCB see diagram 10 3 Close the fascia panel and remove the screws to open the rear cover of control panel see diagram 10 1 Secure the system control cable in the strain relief and thread the cable through rear of the control panel and out of the cables exit see diagram 10 4 Close and secure rear cover of control panel Remove the wire link from the voltage free heating controls connector see diagram 10 1 Connect system controls as diagram 10 5 External controls should be fitted in accordance with the rules in force 10 4 Electrical Connections Testing Carry out preliminary electrical system check
15. Pre heat is a function that provides hot water with minimum delay The ECO setting is recommended and ideally suited to normal family use showers washing up etc Positions between ECO and 4 are for occasional use for water above 55 C approx TO RESET 3 Turn the Mains Reset Switch to 0 wait for 5 seconds turn Mains Reset Switch to 1 the boiler is reset If the fault persists contact your installer service provider using the telephone number on the inside font cover of this booklet TO TURN THE BOILER OFF 4 Turn the Mains Reset Switch to the OFF 0 position Turn the gas supply OFF at the gas service cock if the boiler is to be out of use for some time 002001 3349 02 8 Operating the Boiler User Instructions Digital Display System Pressurisation The digital display normally shows the operating temperature of the unit when there is a central heating demand and gives a pressure reading when there is no demand or when the appliance is in the domestic hot water mode If the digital display shows pressure less than O 7bar re pressurise the system to 1bar by gently opening the built in fillingtap underneath the boiler see diagram 2 Atap extension is provided to facilitate this Ensure the tap is closed If the system repeatedly loses pressure YOU MUST CONTACT YOUR INSTALLER OR GLOW WORM S OWN SERVICE ORGANISATION USING THE TELEPHONE NUMBER ON THE INSIDE FRONT COVER OF THIS BOOKLET To Turn the Boiler Off There is
16. Replace inner casing panel and front casing panel OVERHEAT TH RESET SWITCH Diagram 11 3 12402 GAS OFFSET ADJUSTMENT THROTTLE ELECTRICAL PLUG INLET PRESSURE TEST POINT Diagram 11 4 0020013349 02 11 Commissioning 11 7 Completion Adjust the boiler temperature control and any system controls to their required settings In addition it is necessary to complete the Benchmark logbook For IE itis necessary to complete a Declaration of Conformity to indicate compliance 1 5 813 An example of this is given in the current edition of 1 6 813 Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA ADJUSTMENT 9 SCREW o D Diagram 11 5 11 Commissioning Instructions to the User 11 8 User Controls and Options The mains reset on off switch is used to restart the boiler after a fault condition has occurred i e ignition failure low water pressure or high water temperature The central heating water temperature and hot water temperature control knobs allow the user to setthe temperatures in each mode NOTE If there is no demand the digital display shows the water pressure Temperature Display The digital display normally shows the operating temperature of the unit when there is a central heating demand Holiday
17. and return as soon as possible your guarantee registration card If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow worm Customer Service number 01773 828100 For customer service call 01773 828100 Technical helpline 01773 828300 For General and Sales enquiries Tel 01773 824639 Fax 01773 820569 To register your Glow worm appliance call 0800 073 2142 C Chenchmark gt The code of practice for the installation commissioning amp servicing of gas central heating 0020013349 02 2 Contents The instructions consist of three parts User Installation and Servicing Instructions The instructions are an integral part of the appliance and must to comply with the current issue of the Gas Safety Installation and Use Regulations be handed to the user on completion of the installation CONTENTS INTRODUCTION INSTRUCTIONS FOR USE INSTALLATION INSTRUCTIONS SERVICING INSTRUCTIONS DESCRIPTION Important Information General Information Manual Handling Appliance Safety Devices Maintenance and Servicing Operating the Boiler Technical Information Boiler Location and Ventilation Flue Location and Ventilation Heating System Domestic Hot Water System Installation Preparation Gas Water amp Appliance Connection Safety Discharge Valve and Condensate Connection Flue Preparation Telescopic and Standard Flue Electrical Connect
18. care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs When transferring appliance into roofspace recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required It is assumed safe access flooring and adequate lighting are provided in the roof space Itis tecommendeda risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Unpacking of appliance from carton Recommend 2 persons unpack appliance from carton Always keep working area clear Recommend cut base end of carton and open carton flaps then tilt boiler forwards from its side onto its base and remove carton by sliding up overthe boiler Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required Dispose of packaging in a responsible manner Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance outside packaging Positioning of Appliance for Final Installation no obstructions Recommend 2 persons lift app
19. combustion chamber using a soft brush and vacuum cleaner Carefully flush by spraying water any remaining debris through the condensate trap Ensure the water is kept away from electrical components 12 5 Condensate Drain The condense drain does not normally need removing during servicing To flush the condense drain carefully pour water into the heat exchanger and check that water flows freely to drain If the condense drain is blocked refer to section 14 33 for removal 11502 BURNER SEALING Diagram 12 4 en OFFSET S p v ADJUSTMENT ea aw VALVE GAS PIPE lt RETAINING CLIP dii 7 SEALING GROMMET GAS PIPE 5 RETAINING CLIP N GAS SERVICE COCK Diagram 12 5 HEAT 9 SECURING NUT EXCHANGER 5 OFF SPADE CONNECTOR ELECTRODE Pd LEAD 33 0020013349 02 12 Servicing 12 6 Combustion Check If agas carrying component has been replaced the combustion of the appliance should be checked as follows Once the appliance has been re assembled apart from the front and inner casing panels connect a CO combustion analyser to the test point on the flue adapter see diagram 12 1 Turn on the gas service cock see diagram 7 1 With the power off and the appliance cold unclip the controls fascia and hinge it down to reveal the potentiometers on the rear of the User interface see diagram 12 7 Take care n
20. jig condense pipe and documentation pack see diagram 6 1 and 6 1a The flue is supplied seperately This boiler is for use only on G20 natural gas but the 30cxi may be converted for use on G31 gas Propane L P G Where no British Standards exists materials and equipment should be fit for their purpose and of suitable quality and workmanship The installation of this boiler must be carried out by a competent person in accordance the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements 1 2 Statutory Requirements In GB the installation of the boiler must be carried out by a competent person as described in the following regulations The manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The appropriate Buildings Regulations either The Building Regulations The Building Regulations Scotland The Building Regulations Northern Ireland 0020013349 02 The Water Fittings Regulations or Water byelaws in Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH The Current Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent person and installed in accordance with the current edition of 1 5 813 Domestic Gas Insta
21. shown in diagram 7 1 7 2 Gas Connection Before connection check supply of local gas Refer also to section 1 2 Do not subject the gas service cock to heat Fit the sealing washer into the union nut and make good the connection to the gas service cock on the wall fixing jig see diagram 7 1 Make sure the on off lever is accessible The whole of the gas installation including the meter should be inspected tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of 1 5 813 Domestic Gas Installations 7 3 Water Connections Flush out the domestic hot water and the heating systems before connecting to the boiler Make the connections to the domestic hot water and heating Systems by fitting the sealing washers into the securing nuts and make good the connection to the isolating valves on the fixing jig see diagram 7 1 Do not subject the isolation valves to heat Make sure the drain point is accessible refer diagram 12 10 7 4 Appliance Connection IMPORTANT Withregards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for aone man lift refer to Manual Handling section on page 5 The appliance will contain a small amount of water place a water container beneath the boiler connections before removing the protective caps Position gasket sealing washers and cold water inlet flow restrictor supplied
22. to diagram 9 8 The duct cutting lengths are shown in diagram 9 8 The air duct should be cut at the opposite end to the terminal fixing The terminal plastic duct MUST be cut at the opposite end to the catch The plastic flue duct extensions MUST be cut at the opposite end to seal The cut ducts must be de burred and all filings and debris removed NOTE If you require to lubricate the seals to ease installation please do not use a mineral oil based grease we would recommend the use of water 9 3 Flue Assembly The flue assembly is a push fit design with securing collars Having adjusted the telescopic or cut the air and flue ducts as described in section 9 2 Assemble the flue elbow to the air duct ensuring the correct alignment of the terminal Fit the collar into position mark through two of the pre drilled holes in the collar Remove collar and drilltwo 3mm diameter holes in the elbow take care not to pierce the inner flue duct Insert the terminal flue duct remembering to engage the catch within the terminal check for alignment Fit the rubber sealing collar behind the locating lugs on the flue terminal see diagram 9 1 Push the flue assembly into the wall externally or internally initially until the end of the assembly protrudes a short way from the inside face of the wall This will enable the internal trim ring if required to be positioned and allow the flue duct to be drawn back into the flue elbow af
23. 0020013349 02 06 05 Instructions for Use Installation and Servicing Tobeleft withthe user 12175 24 G C 47 047 23 30cx1 G C No 47 047 24 38CX1 G C No 47 047 27 High Efficiency Condensing Combination Boilers low worm High W WC First Glow worm Nottingham Road Belper Derbyshire DE56 1JT www glow worm co uk Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter for parts In addition this product is guaranteed for 12 months from the date of installation or 18 months from the date of manufacture whichever is the shorter for labour The second year of the parts guarantee from the beginning of the 13th month onwards after installation or manufacture is conditional upon the boiler having been serviced by a CORGI registered gas installer in accordance with the manufacturer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer We recommend you complete
24. 024 20 2000802643 User Interface 24cxi E84020 20 2000802644 User Interface 30cxi 20 2000802645 User Interface 8 i 21 801632 24cxi Burner E84021 21 2000801840 30cxi Burner E88867 21 2000802662 38cxi Burner 2 51 0020013349 02 15 Spare Parts A 2 a Z NS ee gt AAN W Diagram 15 1 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 52 0020013349 02
25. 0cxi only NOTE Steps 11 1 to 11 3 will need to be completed before the appliance can be converted The 30cxi can be converted to run on LPG Propane G31 This conversion should only be carried out by a competent person During the conversion to Propane use of a suitable flue gas analyser is necessary As an option a chargeable boiler only commissioning service can be provided by Glow worm Service by calling telephone No 01773 828100 Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver Ensure that the appliance supply pressure 37mbar 1 2 Access the gas valve Refer to diagram 11 4 and turn the gas valve throttle fully clockwise Turn the throttle back anti clockwise by 5 7 2 turns Ensure that the gas analyser is set to the correct fuel setting Propane Attach combustion analyser to the combustion test point See diagram 12 1 Unclipthe controls fasciato revealthe service potentiometer on the rear of the user interface See diagram 12 7 Turn on the mains electrical supply and turn on the gas service cock Switch the boiler on Ensure external controls are calling for heat The boiler should fire automatically Using an electrical screwdriver rotate the service potentiometer to the mid point or 3 o clock position See diagram 12 7 Thefan speed should now reduceto minimum and 12 should be shown flashing on the digital display Check the CO value If nece
26. 14 2 11486 VENTURI PLATE SECURING SCREW 3 Diagram 14 3 14 Replacement of Parts 14 6 Fan For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove the gas valve as described in the relevant parts of section 14 5 Remove the venturi plate secured with three screws see diagram 14 3 Remove the two screws securing the fan to the gas manifold see diagram 14 4 check the gasket and replace if necessary NOTE The 30 fan is secured through an extension piece with two securing screws check and replace any seals or gaskets if necessary 14 7 Burner For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove the four screws that secure the burner see diagram 14 5 NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED 14 8 Front Insulation For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove burner as per section 14 7 Remove spark electrode see section 14 2 NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED 14 9 Rear Insulation For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove securing screw and washer in the centre of the insulation and withdraw insulation see diagram 14 6 14 10 Viewing Window Fo
27. 4 18 Disconnect the electrical lead by pushing up retaining tab to withdraw the lead plug Remove the retaining clip to remove the low water pressure sensor Fit new O ring Fit the new low water pressure sensor Refill ventand pressurise the boiler Check for leaks 14 24 Bypass For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Refer to diagram 14 19 Remove the retaining clips to remove the bypass tube Fit new O rings Replace the bypass tube refill vent and pressurise the boiler Check for leaks FLOW SENSOR RETAINING CLIP 11497 EBS Diagram 14 17 ELECTRICAL LEAD AND PLUG 11476 LOW WATER PRESSURE SENSOR Diagram 14 18 AUTOMATIC BYPASS VALVE BYPASS TUBE Diagram 14 19 45 0020013349 02 14 Replacement of Parts 14 25 Filling Loop Tube For access refer to section 14 1 Refer to section 12 10 and drain the boiler hot water circuit Refer to diagram 14 20 Remove the retaining clips to remove the filling loop tube Fit new O rings After replacing the filling loop tube open the cold water isolation valve and slowly open a hot water tap to remove air Close the hot water tap and check for any leaks 14 26 Filling Loop Valve For access refer to section 14 1 Refer to section 12 10 and drain t
28. CED PRESSURE FILLING LOOP TAP ZONE VALVE EXTENSION Diagram 4 2 17 METHOD 1 12253 BOILER Double check valve Temporary filling device remove immediately after filling RETURN Drain point Supply METHOD 2 BOILER Back flow prevention device Tundish Supply Diagram 4 3 0020013349 02 5 Domestic Hot Water System 5 1 Water Pressure The maximum working pressure of the domestic hot water circuit is 10 bar If the cold water supply pressure exceeds this then a pressure reducing valve must be fitted in the supply to the boiler 5 2 Hard Water Areas The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework However in areas where the water is hard i e more than 200mg litre it is recommended that the hot water setting is reduced and that a scale reducer is fitted Refer to the manufacturer s instructions or consult the local water company for additional advice 5 3 Domestic Water Flow Rate The water flow rate is restricted to a maximum 8 l min 24 12 l min 30 and15 5 l min 38cxi by a restrictor fitted during boiler installation see diagram 7 1 6 Installation Preparation 6 1 Appliance Pack IMPORTANT With regards to the Health and Safety Manual Handling requirements two persons shall be required to lift the appliance r
29. M SURFACE OR A BOUNDARY FACING THE TERMINAL 600 K FACING TERMINALS 1200 L FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 M VERTICAL FROM A TERMINAL 1500 N HORIZONTALLY FROM A TERMINAL 300 VERTICAL FLUES P FROM ANOTHER TERMINAL 600 Q ABOVE ROOF LEVEL 300 R FROM ADJACENT OPENING WINDOW 1000 S FROM ADJACENT WALL TO FLUE 300 Diagram 3 5 3 4 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram 3 5 For Ireland the minimum distances for flue terminal positioning must be those detailed in 1 5 813 Domestic Gas Installations The terminal must be exposed to the external air allowing free passage of air across it at all times Being a condensing boiler some pluming may occur from the flue outlet This should be taken into consideration when selecting ihe position for the terminal Seediagram 3 5 These dimensions comply with the building regulations but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions Increased siting flexibility can be achieved by using the Glow worm Plume Management Kit A2044000 black or A2044100 white NOTE If necessary it is permitted to increase the terminal protrusion through the outside wall to greater than the minimum dimension of 87mm but no more than 600mm see diagram 1 1 Carports or similar extensions of a roof
30. P FILLING LOOP VALVE TUBE Diagram 14 20 11477 REDUCED PRESSURE ZONE VALVE Diagram 14 21 14 Replacement of Parts 14 30 Central Heating Filter Refer to section 12 8 Fit new O rings 14 31 Heating Circuit Drain Point Refer to section 12 9 to drain the boiler heating circuit Refer to diagram 14 22 Remove the retaining clip to remove the drain point Fit new O rings Replace the drain point refill vent and pressurise the boiler Check for leaks 14 32 Inner Casing Panel Seal For access refer to section 14 1 Refer to diagram 12 11 Remove the inner casing panel To replace remove the old seal thoroughly clean the casing surfaces Fit the new seal it is supplied to the correct length Refit the inner casing panel NOTE Ensure the seal is fitted correctly giving an airtight joint 14 33 Plate to Plate Heat Exchanger For access refer to section 14 1 Refer to section 12 9 to drain the boiler heating circuit Refer to section 12 10 and drain the boiler hot water circuit Refer to diagram 14 23 Remove the gas supply pipe from the gas service cock and the gas valve refer to relevant parts of section 12 3 Undo the central heating flow pipe connection into the left hand hydroblock see diagram 14 23 Undo the nut connecting flow pipe to heat exchanger see diagram 14 15 Lift it up to remove it from the hydroblock with the washer and rotate it f
31. PLATE HEAT 10 EXCHANGER SECURING SCREW SAFETY DISCHARGE 12950 LH VIEW SECURING HYDROBLOCK CLIP 2 SECURING CLIP 1 RH OUTLET HYDROBLOCK CONNECTOR S D SECURING PLATE TO PLATE HEAT CLIP 3 EXCHANGER SECURING SCREW 7 x SECURING CLIP 4 Diagram 14 23 DIVERTER VALVE L H HYDROBLOCK Diagram 14 24 MAINS RESET SWITCH 11416 KNOB RETAINING N MAINS RESET KNOB E Diagram 14 25 49 0020013349 02 14 Replacement of Parts 14 42 Control Box For access refer to section 14 43 Remove relevant plugs and connectors refer to wiring diagram 13 1 Withdraw grommets and leads so they are hanging loose Unthread the retaining cord and remove the control box by drawing it outwards away from its retaining slots see diagram 14 26 14 43 Fuse Main PCB Control Box For access refer to section 14 43 The fuse is located at bottom right hand side of the PCB see diagram 13 1 or 14 26 14 44 User Interface Refer to section 14 38 for access Remove electrical plug Remove the securing screws see diagram 14 27 Withdraw the board When replacing the board refer to instructions supplied with replacement PCB on setting it up RETAINING SLOTS TORX SCREWS 3 RETAINING CORD REAR PANEL MAIN PCB PCB RETAINING CLIPS Diagram 14 26 14 45 230V Controls Interface F
32. RCLIP STEEL k WASHER Diagram 14 7 SECURING UPPER SUPPORT amp 9 BOLT BRACKET O Eo EXPANSION VESSEL EZ COUPLING Diagram 14 8 14 Replacement of Parts 14 16 Safety Discharge Valve For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Refer to diagram 14 13 Undo the safety discharge valve union and remove from the pipework Remove the securing clip and withdraw the safety discharge valve Fit new O ring Refill vent and pressurise the boiler Check for leaks RETAINING CLIP NOTE ORIENTATION a 10066 DIVERTER VALVE DIVERTER VALVE ELECTRICAL PLUG Diagram 14 11 SECURING SCREWS AND CLAMPS FLOW AND RETURN PIPE NUTS X 11490 CAP HEAD SCREW 4 11496 CABLE COVER Diagram 14 12 SECURING A SCREWS Diagram 14 10 o n Om I lt Q m Ne 11694 Diagram 14 13 43 0020013349 02 14 Replacement of Parts 14 17 Domestic Hot Water Thermistor For access refer to section 14 1 Refer to section 12 10 and drain the boiler domestic hot water circuit Refer to diagram 14 14 Disconnect the domestic hot water thermistor electrical connections Remove hot water thermistor and retaining clip Remove domestic hot water thermistor from clip
33. RGE D H W COLD VALVE INLET FILTER C H RETURN FILTER DRAIN 6 COLD RETURN OUTLET DHW INLET DISCHARGE THERMISTOR SCHEMATIC LAYOUT OF BOILER Diagram 1 3 TABLE 2 24 cxi 9 1 0 2 0 5 9 3 0 3 0 5 BURNER Case Off CO Case On MIN MAX APPROXIMATE GAS RATE mr h 0 48 2 24 after 10 mins from cold ft h 16 8 79 30 cxi 9 1 0 2 0 5 9 3 0 3 0 5 BURNER Case Off APPROXIMATE MIN MAX GAS RATE mV h 0 48 2 8 after 10 mins from cold ff Rh 16 8 99 38 cxi BURNER Case Off 8 8 0 2 0 5 9 0 0 3 0 5 APPROXIMATE MIN MAX GAS RATE m h 0 62 3 6 after 10 mins from cold 21 8 127 2 Boiler Location and Ventilation 2 1 Location This boiler is not suitable for outdoor installation This boiler may be installed in any room although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements This boiler is suitable for installation in bathroom zones 2 and 3 In GB this is the current WIRING REGULATIONS BUILDING REGULATIONS In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules 2 2 Clearances The boiler should be positioned so that at least the minimum operational and servicing clearances are pro
34. TER THERMISTOR NOTE Position thermistor within the area indicated Diagram 14 14 RETURN HEAT 2 PIPE EXCHANGER FLOW PIPE OVERHEAT THERMOSTAT 1 9 1 M TA RETURN FLOW THERMISTOR THERMISTOR Diagram 14 15 AUTOMATIC m AIR VENT 3 Diagram 14 16 12938 14 Replacement of Parts 14 22 Flow Sensor For access refer to section 14 1 Refer to section 12 10 and drain the boiler hot water circuit Refer to diagram 14 17 Remove the clip securing the filling loop tube to the domestic water filter housing see diagram 14 20 Pull the tube forward to disengage it before rotating it down and out of the way Undo the brass securing nut above the cold water inlet valve Remove the securing clip between the domestic water filter housing and the flow sensor see diagram 14 17 Disengage the domestic water filter housing by lifting it up and out Remove the electrical connection to the flow sensor Remove the securing clip between the flow sensor and the hydroblock Remove flow sensor Fit new O rings After replacing the flow sensor open the cold water isolation valve and slowly open a hot water tap to remove air Close the hot water tap and check for any leaks 14 23 Low Water Pressure Sensor For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Refer to diagram 1
35. TITUTES AIR BREAK 12333 MIN DIA 21MM NO RESTRICTION ON LENGTH MIN DIA 21MM NO RESTRICTION ON LENGTH 2 5 FALL CEMENT MORTAR SEALING 100MM PLASTIC TUBE BOTTOM OF TUBE SEALED HOLE DEPTH 400MM 300MM External Termination into Soakaway 2 ROWS OF 3 x 12MM HOLES AT 25MM CENTRES 50MM FROM BOTTOM OF TUBE HOLES TO FACE AWAY FROM HOUSE Diagram 8 3 23 0020013349 02 9 Flue Preparation Telescopic and Standard Flue 9 1 Flue Components Additional flue accessories are available to suit your site ee mm conditions see diagram 9 2 The components supplied in the Standard and Telescopic kit are shown in diagram 9 1 The Glow worm Flue Options Guide available on request or through the web site describes in detail the necessary accessories Top Outlet Horizontal Concentric Flue Packs FLUE A2043600 Horizontal telescopic flue pack ELBOW A2043400 Standard horizontal flue pack SECURING SCREW x 4 COLLAR SEALING TAPE telescopic only SCREW x 2 GASKET SEALING fitted COLLAR T SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY SEALING COLLAR STANDARD TERMINAL ASSEMBLY Diagram 9 1 45 Bend 2 9 2000460485 lt lt 20ff 90 Bend 2000460484 0 5m EXTENSION 2000460481 im EXTENSION 2000460482 L VERTICAL 4 FLUE ADAPTOR 2m A2024600 EXTENSION 2000460483 Diagr
36. The pump expansion vessel and associated safety devices are all fitted within the boiler Once the controls are set the boiler operates automatically Please read these instructions and follow them carefully for the correct installation and economical use of your boiler Water Treatment Inthe case of an existing installation it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed For optimum performance after installation of a new system the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 1992 using acleanser such as Sentinel X300 or X400 Fernox restorer or Salamander corrosion guard cleaner For long term corrosion protection after flushing an inhibitor suitable for stainless steel exchangers should be used refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems Examples are Sentinel X100 Fernox protector or Salamander corrosion guard inhibitor Compartment or Cupboard Installations If the boiler is fitted into a compartment or cupboard it does not require ventilation openings Do not use the compartment or cupboard for storage Clearances If fixtures are positioned close to the boiler space must be left as shown in section 2 Enough space must also be left in front of the boiler to allow for servicing Condensate Drain The condensate drain see section 8
37. a mains reset switch on the right hand side of the controls fascia which will isolate the boiler However it is preferable to leave the electrical supply on whenever possible to permitoperation ofthe built in frost protection see Protection Against Freezing and daily pump and valve exercise To turn off the central heating use the room thermostat or programmer To turn off the domestic hot water turn the hot water temperature control knob to the minimum setting For holiday mode turn both of the temperature knobs to the minimum setting To turn off the boiler for servicing isolate it from the electrical supply To turn it on again follow the instructions given in Operation of the Boiler 4 b L v lt A C FILLING LOOP TUBE FILLING LOOP TAP AND EXTENSION Diagram 2 0020013349 02 1 Technical Information THIS DIMENSION CAN BE INCREASED TO 600mm MAX CENTRAL HEATING DOMESTIC WATER GAS CONNECTION GENERAL ARRANGEMENT 5 N 14 FLUE m 7 CENTRE LINE ooo oo PENES 4 FLUE 1 d l BOILER 715 SAFETY DISCHARGE DRAIN 117 Y 22 1 21 GAS 86 tis 34 450 Diagram 1 1 1 1 IMPORTANT NOTICE The boiler is supplied in one carton which includes a fittings pack pipe pack fixing
38. a trap may cause the boiler siphon to work incorrectly Refer to BS5546 or BS6798 for advice on disposal of boiler condensate 002001 3349 02 22 SAFETY DISCHARGE 0 VALVE po pam 11694 UNION NUT Tighten half turn ge past finger tight SAFETY DISCHARGE VALVE TUBE Diagram 8 1 CONDENSATE 5 TRAP lt gt CONDENSATE DRAIN CONNECTOR Diagram 8 2 8 Safety Discharge Valve and Condensate Connections Typical Gravity Draining Condensate Installations INTERNAL SOIL AND VENT STACK MIN DIA 21MM NO RESTRICTION ON LENGTH Internal Soil and Vent Pipe EXTERNAL LENGTH OF PIPE 3M MAX MIN DIA 21MM OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND BUT ABOVE WATER LEVEL NOTE FOR EXTENDED PIPE RUNS 32MM DIA PIPE SHOULD BE USED External Termination to a Gulley or Hopper MIN DIA 21MM NO RESTRICTION ON LENGTH OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL Internal Termination Downstream of Sink Waste NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5 44mm FOR EVERY 1M External Soil and Vent Pipe or Rainwater Pipe Internal Termination into Combined Sink Waste EXTERNAL SOIL AND VENT STACK EXTERNAL MAX 3M SINK 21MM TERMINATION FROM APPLIANCE NOTE FOR EXTENDED PIPE RUNS 32MM DIA PIPE SHOULD BE USED CONS
39. all at this angle a 125mm hole should be drilled irrespective of internal or external installation Remove the wall template whilst drilling the flue hole 6 4 Fixing Jig Reposition the wall template over the flue hole and mark the position of the fixing holes for the fixing jig see diagram 6 3 Drill the required fixing holes and insert suitable wall plugs NOTE Due tothe varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable Secure the fixing jig to the wall 0020013349 02 eo 2 5 44mm metre a Inclined Extended flue length 176 WALL TEMPLATE a N Ng 90 Su i Standard 125 flue length Horizontal EXTENDED SIDE FLUE Diagram 6 2 Q WALL ES TEMPLATE FIXING JIG Diagram 6 3 7 Gas Water amp Appliance Connection 7 1 System Connection The system can now be connected without the boiler being mounted All water and gas connections are on the fixing jig with the exception of the condense drain and safety discharge the positions of these are shown on the wall template The gas supply pipe must be chased into the wall if routed up the back of the boiler A Vertical Plumbing Kit can be used to route the central heating or DHW pipes see section 1 6 Make connections to fixing jig gas water and heating cocks with the tube assemblies supplied in fixing pack as
40. am 9 2 0020013349 02 24 9 Flue Preparation Telescopic and Standard Flue 9 2 Flue Length Top Rear flue Standard with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 9 3 Ifthe measurement Y exceeds 652mm then the appropriate length of extension pipe is required The minimum dimensionis 187mm to suita 75mm min wall thickness Top Rear flue Telescopic with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 9 4 Ifthe measurement Y exceeds 525mm then the appropriate length of extension pipe is required if the dimension is less than 320mm DO NOT cut the flue it can project to a maximum of 600mm if this is not desirable then a Standard flue MUST be used and cut to length Top Side flue Standard with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 9 5 If the measurement Y exceeds 652mm then the appropriate length of extension pipe is required The minimum dimension for Lhd is 270 and Rhd 242 to suit a minimum wall thickness of 75mm Y WALL THICKNESS 112 osi DRILL AND COLLAR OUTSIDE BOILER WALL FACE MOUNTING WALL TOP REAR FLUE STANDARD Diagram 9 3 E Y D WALL THICKNESS 112 DRILL AND SCREW TOP REAR FLUE TELESCOPIC
41. ands before eating drinking or going to the lavatory If you do suffer irritation to the eyes or severe irritationto the skin seek medical attention Electrical Supply The boiler must be earthed All system components shall be of an approved type and all wiring to current wiring regulations External wiring must be correctly earthed polarised and in accordance with the relevant standards In GB this is BS 6891 In IE this is the current edition of 1 5 813 Domestic Gas Installations The boiler must be connected to a permanent 230V ac 50Hz supply Connection of the whole electrical system of the boiler including any heating controls to the electrical supply must be through one common isolator and must be fused 3 Amp maximum Isolation should be by a double pole switched fused spur box with a minimum gap of 3mm for both poles The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3 pin plug both to the current issue of BS 1363 may be used provided they are not used ina room containing a bath or shower Wiring to the boiler must be PVC 85 C insulated cable not less than 0 75mm 24 0 20mm General Information General Note This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation
42. as the built in frost protection and pump valve saver program would not be operable Reminder leave these instructions and the Benchmark logbook with the user 0020013349 02 12 Servicing Important Notes To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation and usage but in general once a year should be enough It is the Law that any servicing is carried out by a competent person When replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm 12 1 General Refer to Table 2 Section 1 Technical Information Measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point see diagram 12 1 IMPORTANT NOTE Products of combustion willbe discharged when the cap is removed It is important to replace the cap immediately Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve see diagram 7 1 All routine servicing requirements can be achieved by the removal of the front panel and inner panel only To rem
43. at stat operated Maximum temperature exceeded Check thermistor connections Air in system with thermistor at maximum setting Faulty overheat stat connection Check that pump is wired into appliance and not from programmer This would cause no pump overrun Central heating flow thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe Domestic Hot Water thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe Water pressure sensor fault Faulty sensor connection Check wiring Central heating return thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe Main board connection fault Check wiring between mainboard and user interface User interface connection fault Check wiring between mainboard and user interface Main PCB connection fault Check connections and wires Central heating flow temperature is greater than 95 C System fault Possible pump failure Check Thermistor on flow Flame detection fault flame presence for more than 5 seconds after burner stop Gas valve defective Power supply is less than 170V Check electrical supply polarity User interface fault Faulty User Interface Central heating thermistor unplugged Check Thermistor connection Software incompatib
44. ccess as follows Hinge down the control box and remove Torx screws and unhook the rear panel refer diagram 12 2 Refer to the Wiring diagram 13 1 and fault finding charts diagrams 13 2 and 13 3 002001 3349 02 36 13 Fault Finding e e N r w r WATER FAN Q PRESSURE 5 SENSOR GAS IGNITION CONTROL ELECTRODE VALVE Q OVERHEAT IGNITER THERMOSTAT UNIT 5 S bk w THERMISTOR bk CH FLOW THERMISTOR CH RETURN PP 230V SWITCHED LIVE FROM OPTIONAL FROST LE 230V SWITCHED LIVE FROM HEATING CONTROLS DO NOT CONNECT 9 FLOW SENSOR CONTROLS VOLTAGE FREE INTERFACE HEATING CONTROLS PLUG Stee REMOVE THE LINK IF FITTING VOLTAGE FREE OR 230V L SYSTEM CONTROLS IF THE LINK IS NOT REMOVED THE BOILER WILL RUN CONTINUOUSLY CHASSIS EARTH g y g y m san on THERMISTOR HOT WATER 630 mAT gy b I I br 230V 50Hz bk BLACK br BROWN r RED HA PERMANENT w WHITE or ORANGE v MAINS SUPPLY g y GREEN gn GREEN ON OFF FUSED AT 3A y YELLOW SWITCH Diagram 13 1 37 0020013349 02 13 Fault Finding 12190 START Is the system pressure displayed Check there is no demand z YES Replace pressure sensor Adjust system pressure if there is no change Is it flashing indicating zero Set a demand for C H on NO
45. ctrical plug Undo two securing screws and withdraw programmer 14 38 Diverter Valve Motor For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Refer to section 12 10 and drain the boiler hot water circuit Remove the diverter valve motor as described in section 14 14 Refer to section 14 35 to remove the left hand hydroblock Unscrew and remove both halves of the diverter valve from the left hand and right hand sides of the hydroblock see diagram 14 24 When replacing the two halves of the diverter valve it is important to ensure the spindle is located correctly This can be observed with the left hand hydroblock removed 14 39 Mains Reset Switch Refer to section 14 38 for access Remove the switch retaining screw Remove switch from housing see diagram 14 25 Remove electrical leads 14 40 Mains Reset Knob Refer to section 14 38 for access Remove actuator by springing back retaining clips see diagram 14 25 Spring back knob retaining clips and push knob out from the back 14 Replacement of Parts 14 41 Main PCB For access refer to section 14 1 Hinge down the control box Remove TORX screws and unhook the rear panel Remove the electrical connections to the PCB Prise back the two PCB retaining clips and withdraw the PCB see diagram 14 26 When refitting the rear panel ensure the leads are not trapped refer to diagram 14 26 CENT HEATING PLATE TO
46. e spark electrode carefully from the combustion chamber see diagram 12 3 14 3 Igniter Unit For access refer to section 14 1 Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws see diagram 14 1 14 4 Ignition Lead For access refer to section 14 1 Refer to diagram 12 6 Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit see diagram 14 1 14 5 Gas Valve For access refer to section 14 1 Remove the electrical plug from the gas valve see diagram 14 2 Refer to section 12 3 for removal of the fan gas valve and burner assembly Before removing the gas valve note its position on the fan Remove the three securing screws which fix the gas valve and plastic swirl plate to the venturi on the fan see diagram 14 3 Remove the gas valve When re fitting the gas valve take care as it can be fitted more than one way After re fitting check the combustion CO and adjust if necessary See section 12 6 After assembly testfor gas soundness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 5 813 Domestic Gas Installations 002001 3349 02 SECURING SCREWS 2 IGNITER UNIT ELECTRICAL CONNECTIONS SPADE CONNECTOR 2 2 LEAD Diagram 14 1 12402 ELECTRICAL PLUG PRESSURE TEST POINT Diagram
47. e that a watertight seal is achieved but do not use excessive force Remove the siphon adaptor from the flexible tubes using a suitable container flush the heat exchanger until the water SIPHON ADAPTER FLOAT CONDENSE appears clear in the container Diagram 14 29 12764 SCREW 15 Spare Parts When ordering spare parts contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance and serial number to be found on the data label If ordering from British Gas also quote the G C number of the part Key No Part No Description GC Part No 1 801724 Overheat Thermostat E83996 2 2000801911 System Pressure Sensor E83997 3 2000801831 Plate to Plate Heat Exchanger E83998 4 801192 Diverter Valve Motor E27211 5 801637 Electrode E83999 6 2000801904 Safety Discharge Valve E84000 7 2000801898 Automatic Air Vent E84001 8 2000801897 Central Heating Filter E84002 9 801722 Heating flow thermistor Heating return thermistor E84003 10 801649 Gas valve E84004 10 802172 Gas valve 38cxi only E97505 11 801809 Mains Reset Switch E84794 12 801906 Domestic Cold Water Inlet Filter 13 2000801910 Flow Sensor E84014 14 801655 Igniter Unit E84015 15 2000801909 By pass E84016 16 2000801923 230V Controls Interface E84018 17 4000124180 Main P C B E84019 18 2000801380 Pump head only E88868 19 801645 Fan E84
48. efer to Manual Handling section on page 5 Please check the boiler contents as shown in diagrams 6 1 and 6 1a NOTE The fittings pack pipe pack and document pack are located in the polystyrene packing on the top of the boiler The flexible condensate outlet pipe is located in the base polystyrene packing under the boiler base Remove the polystyrene end packing pieces then carefully lay the boiler on its back remove the two front casing panel securing screws and lift off the panel from two retaining lugs Remove the transit packaging behind the front panel and discard Carefully place front panel and screws to one side 0020013349 02 18 FIXING JIG Diagram 6 1 6 Installation Preparation N D N MAINS VOLTAGE gt SEALING WASHER 12x18x2 HEATING CONTROL Kx CONNECTION PLUG SEALING WASHER 18x23x1 5 FLUE SEALING WASHER 14x18x1 5 EE om Q9 SEALING WASHER 16x24x1 5 FILLING FLOW RESTRICTOR BEVIGE EXTENSION FITTINGS PACK HEATING HEATING aries FLOW FLOW GAS SUPPLY SAFETY PIPE DISCHARGE VALVE PIPE COLD WATER INLET PIPE D HEATING j NN RETURN eo PIPE CONNECTION PIPE he A 1 CON HEATING Z Q PIPE PACK DOCUMENTATION PACK Not illustrated FLEXIBLE 2 ap oe Instructions CONDENSATE 5 an I f OUTLET PIPE ombi Cover Leaflet Wall template LOOSE ITEMS Diagram 6 1a 19 0020013349 02 6 Installation Preparation 6 2 Wall Template
49. emove the filling loop tube refer to section 14 25 Remove the bypass tube refer to section 14 24 Remove the electrical connections to the flow sensor and the low water pressure sensor refer to sections 14 22 and 14 23 Remove the water connection clips 3 and 4 below the hydroblock see diagram 14 23 0020013349 02 48 Remove the central heating filter refer to section 12 8 Remove the retaining clip to remove the drain point refer to section 14 31 Undo two securing screws on underside of the right hand hydroblock Remove right hand hydroblock from plate to plate heat exchanger using a TORX screwdriver to remove the securing screw see diagram 14 23 Lift out the right hand hydroblock Remove the remaining components for refitting into the replacement right hand hydroblock Refill vent and pressurise the boiler Open the cold water isolation valve and slowly open a hot water tap to remove air Close the hot water tap Check for leaks 14 36 Access to Switches User Interface and Programmer For access refer to section 14 1 Release the front of the fascia by carefully prising up the two retaining latches see diagram 14 26 Do not allow the front of the fascia to swing down and be loosely held by the electrical connections to the mains reset switch user interface and clock Either remove the connections or support the fascia 14 37 Programmer if fitted Refer to section 14 38 for access Remove ele
50. f and disconnect pressure gauge In the unlikely event that the gas valve needs adjusting refer to section 12 6 Re setting of the gas valve requires a combustion analyser and any adjustment should only be carried out by a competent person Note that the burner pressure cannot be measured at the gas valve as it is altered by the suction of the fan and modulated according to demand 11 6 Testing Heating System Check that all remote controls are calling for heat The boiler will fire automatically Fully open all radiator valves flow control valve A if fitted see diagram 4 1 Balance the radiators as required and if fitted adjust valve A to give the required system differential Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of 20 C can be achieved across flow and return This boiler has a built in bypass see diagram 11 5 The boiler is supplied with the bypass open half a turn It should not be necessary to adjust the bypass but if required turn the adjustment screw clockwise to close the valve see diagram 11 5 Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply Drain the entire system rapidly whilst hot using the drain tap at the lowest part of the system Fill and vent the system as described previously in section 11 2 Lock or remove the handle from control valve A if fitted
51. g lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip Always use assistance if required Removal of carton from delivery van Recommend 2 person lift or 1 person with use of sack truck If 1 personis performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible lf 2 persons performing lift ensure co ordinated movements during lift Always use assistance if required Carriage of carton from point of delivery to point of installation ground floor Recommend 2 person lift or 1 person with use of sack truck If 1 personis performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend
52. he boiler hot water circuit Refer to diagram 14 20 Remove the clip securing the filling loop valve to the domestic water filter housing Disengage by pulling forward Remove the clip securing the filling loop to the filling loop valve Remove the filling loop valve from the filling loop Fit new O rings After replacing the filling loop valve open the cold water isolation valve and slowly open a hot water tap to remove air Close the hot water tap and check for any leaks 14 27 Automatic Bypass Valve For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Refer to diagram 14 19 Remove the retaining clip to remove the bypass valve Fit new O rings Replace the bypass valve refill vent and pressurise the boiler Adjust the bypass as described in commissioning see section 11 6 Check for leaks 14 28 Reduced Pressure Zone Valve For access refer to section 14 1 Refer to diagram 14 21 Refer to section 14 25 to remove the filling loop Remove the retaining clip to remove the reduced pressure zone valve Fit new O rings Replace the reduced pressure zone valve refill vent and pressurise the boiler Check for leaks 14 29 Domestic Cold Water Inlet Filter For access refer to section 14 1 Refer to section 12 7 Fit new O rings 0020013349 02 46 RETAINING RETAINING d FILLING LOO
53. he cold water isolating valve and test the Domestic Hot Water circuit for soundness Check for leaks 12 8 Central Heating Return Filter Turn off the electrical supply to the boiler Refer to section 12 9 and drain the heating circuit of the boiler Remove the filter retaining clip and filter clean or renew if necessary see diagram 12 9 Refit the filter ensuring the correct orientation The flat and hole in the filter as shown in diagram 12 9 Secure with retaining clip Open the heating flow and return isolating valves and refill vent and pressurise the heating circuit See section 11 2 Check for leaks 12 9 Draining of Boiler Heating Circuit Drain down the Heating Circuit of the boiler only by closing the heating flow and return isolating valves on the wall mounting jig See diagram 7 1 Attach a length of hose to the drain point and open the drain valve see diagram 12 10 After servicing or replacing parts close the drain valve and remove the hose Open the heating flow and return isolating valves and refill vent and pressurise the heating circuit See section 11 2 Check for leaks 12 10 Draining of Boiler Hot Water Circuit Drain the Domestic Hot Water circuit by closing the cold water isolation valve on the wall mounting jig Open one or more hot water taps to drain the hot water circuit After servicing or replacing parts open the cold water isolation valve and slowly open a hot water tap to remove air
54. he necessary accessories These instructions describe the use of the standard and telescopic horizontal flues The instructions for all other flues will be contained in those packs 12839 WALL THICKNESS 75 min to 540 max OUTSIDE WALL FACE BOILER MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max TOP REAR FLUE STANDARD Diagram 3 1 NOTE If necessary it is permitted to increase this dimension to 600mm max 5 87min Max flue length 717mm EL J 20mm min clearance 239 211 A FLUE OUTSIDE INTERNAL WALLFACE SURFACE Max distance from outside Min distance from outside wall face to min clearance wall face to min clearance LH 458mm LH RH 75mm RH 486mm TOP SIDE FLUE STANDARD Diagram 3 2 3 2 Flue Length The maximum permissable horizontal flue length is 10 metres plus the flue terminal this can be achieved by use of the accessories however should additional 90 or 2 x 45 elbows be used then the length MUST be reduced by 1metre When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2 5 44mm metre to allow condensate to run back into the boiler and out via the drain The flue can be installed from inside the building when access to the outside wall face is not
55. heat exchanger Undo the two nuts of the flow and return pipes from the heat exchanger Move the pipes away from the heat exchanger Loosen the three heat exchanger securing screws and clamps two at the top and one at the bottom to remove the heat exchanger see diagram 14 9 CAUTION There will be water in the heat exchanger Remove condense pipe connector from bottom of heat exchanger Carefully ease heat exchanger out 14 13 Flue Hood For access refer to section 14 1 Remove heat exchanger as per section 14 12 Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow see diagram 14 10 14 14 Diverter Valve Motor For access refer to section 14 1 Refer to diagram 14 11 Remove the electrical plug Remove the retaining clip Ease the diverter valve motor from its housing and remove 14 15 Pump head only For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Refer to diagram 14 12 Remove the four cap head screws Carefully remove the pump head together with cable Do not strain cable Support the pump head unscrew cable cover at the side of pump head and take off Disconnect wiring from pump head Reconnect wiring to new pump head and fit cover Fit the new pump head with O ring Refill vent and pressurise the boiler Check for leaks 0020013349 02 42 FIBRE WASHER GLASS CI
56. ility Incorrect user interface or Main PCB Central heating return temperature is greater than 90 C System fault Possible pump failure Check Thermistor on return Maximum temperature rise slope Possible pump failure Air in system Maximum delta temperature 39 Check Thermistor on return System too restrictive Diagram 13 3 0020013349 02 14 Replacement of Parts 14 1 General Replacement of parts must be carried out by a competent person Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler see diagram 7 1 Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls For replacement of parts the front casing and the inner casing panel of the boiler will need to be removed To remove undo the two screws on the underside of the front casing and lift off Undo the two screws on the front of the inner front panel and lift off The side panels can be hinged sideways to aid replacement of parts To hinge a side panel undo and remove the three screws securing each side panel to the boiler two at the front and one at the top 14 2 Spark Electrode For access refer to section 14 1 Remove the spark plug lead earth lead and two securing screws Withdraw th
57. in the fittings pack as shown in diagram 7 1 Lifting the boiler into position lean the top of the boiler slightly to the wall and position just above the hanging bracket Lower the boiler slowly and engage onto the hanging bracket Position gasket sealing washers and cold water inlet flow restrictor supplied in the fittings pack as shown in diagram 7 1 Make good the final connections L Sealing washer 12x18x2 Sealing washer 18x23x1 5 O N Sealing washer 14x18x1 5 P Sealing washer 16x24x1 5 R Flow restrictor Sy A Central heating isolation valve Flow B Domestic hot water isolation valve C Gas service cock isolation valve D Domestic cold water inlet E Central heating isolation valve Return F Safety discharge outlet G 22mm inlet pipe fitting H 15mm inlet pipe fitting J Boiler connections K Gas connection pipe 12769 ALL ISOLATION VALVES ARE SHOWN IN CLOSED POSITION NOTE One additional washer for each size M N is supplied as spare Diagram 7 1 21 0020013349 02 8 Safety Discharge Valve and Condensate Connections 8 1 Safety Discharge Valve The pipe from the safety discharge valve must not discharge above an entrance window or any type of public access area Take the short safety discharge tube union nut and seal supplied loose in the boiler fittings pack and fit as shown in diagram 8 1 This must be extended using not less than 15mm
58. ion Commissioning Servicing Fault Finding Replacement of Parts Spare Parts SECTION PAGE No oNN 0020013349 02 Important Information WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately Eliminate all sources of ignition i e smoking blowlamps hot air guns etc Do not operate electrical lights or switches either on or off Open all doors and windows ventilate the area Sheet Metal Parts This boiler contains metal parts components and care should be taken when handling and cleaning with particular regard to edges Sealed Components Under no circumstances must the User interfere with or adjust sealed parts Gas Category This boiler is for use only on G20 natural gas but the 30cxi may be converted for use on G31 gas Propane L P G Gas Safety Installation and Use Regulations In your own interests and that of safety it is the Law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations Testing and Certification This boiler is tested and certificated for safety and performance It is therefore important that no alteration is made to the boiler without permission in writing by Glow worm Any alteration not approved by Glow worm could invalidate the certification boiler warranty and may also infringe the current issue of the statutory requirements CE Mark This boiler meet
59. itial Lighting The lighting procedure of the boiler is fully automated Check that all external controls are calling for heat Ifthe integral programmer is fitted check that it is correctly programmed and if necessary overridden to provide heat Ensure that both the central heating water temperature and the hot water temperature control knobs are turned OFF 0 Turn onthe mains electrical supply and the mains reset knob to on the controls fascia Turn the central heating water temperature control knob to I MINIMUM The digital display will show water temperature in central heating demand The fan should start and after a few seconds the ignition will commence If the burner fails to light the fan will stop Initially this may be due to air in the gas supply line The boiler will automatically have three attempts at ignition If necessary turn the reset switch to the off position 0 then back to the on position I and the boiler will restart After the boiler has lit allow to warm at MINIMUM temperature setting to purge any air from the system NOTE If the appliance is operated above MINIMUM on initial lighting there is a possibility that the overheat thermostat will trip and F5 will be displayed on controls fascia this is due to air not having been completly purged See diagram 11 3 for reset switch Once the system has been purged of air turn the Hot water temperature control knob to the desired position and o
60. let Do not operate the boiler without water Check that the electrical supply to the boiler is ON and set any remote controls as required With the User controls in their OFF 0 positions turn the Mains Reset Switch to the ON 1 position the running lamp will initially illuminate green then go off the system pressure will be displayed and should read on the digital display at least 0 7bar recommended 1 0bar if less pressurise as described in the System Pressurisation section USER CONTROLS CENTRAL HEATING CONTROL 1 Turn the central heating water temperature control ON the lighting sequence will begin the running lamp will illuminate green to indicate the boiler has the system temperature will now be displayed instead of system pressure The temperature of the central heating water can be adjusted by turning the central heating water temperature control to desired setting between 1 Min and Maximum setting is appoximately 82 C Set the control O to switch off heating If the boiler fails to light reset the controls see paragraph below TO RESET If a fault occurs the running lamp will flash red and a fault code will appear on the digital display DOMESTIC HOT WATER CONTROL 2 Position 0 hot water OFF Turn hot water temperature control between 0 to for hot water 62 C with no pre heat Turn hot water temperature control between 2 and for hot water 40 C 62 C with pre heat
61. let valve slots in line with the length of the valve see diagram 7 1 To enable the system pressure to be viewed turn the Central heating temperature knob and hot water temperature knob to the off position Turnthe mains electricity supply on to the appliance and ensure that the mains switch on the appliance fascia is set to the on position The system pressure is displayed on the controls panel fascia of the appliance see diagram 1 of the User Instructions Fill the system until the pressure on the display reads at least 1 0bar Note that on filling the system a small amount of water may be discharged from the reduced pressure zone valve see diagram 4 2 Remove the two inner casing panel securing screws lift the panel off the retaining lugs refer diagram 11 1 Make sure that the automatic air vent works correctly and that the black cap is loosely fitted to allow air to escape see diagram 11 2 Check the heating system and boiler connections for water soundness INNER CASING 12353 CASING PANEL N SECURING SECURING SCREW SCREWS Uai i Diagram 11 1 i AUTOMATIC AIR VENT CAP Diagram 11 2 0020013349 02 11 Commissioning 11 3 Preparation for Lighting Isolate the boiler from the mains electrical supply Test for gas soundness and purge air from the gas supply Turn on the gas service cock see diagram 7 1 11 4 In
62. liance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure stable balance achieved and lift upwards to position in place on bracket Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feetinstead Keep boiler as close as possible to body throughout lift to minimise strain on back Ensure co ordinated movements to ensure equal spread of weight of load Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance 0020013349 02 Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc Recommend 2 persons lift appliance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to position in place on bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist
63. llations the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation In GB the following Codes of Practice apply BS4814 BS6798 BS5440 Part 1 and 2 BS5546 Part 1 BS5449 BS6891 BS6700 BS7074 Part 1 and 2 BS7593 BS7671 In IE 1 5 813 BS5546 BS 5449 BS 7074 BS 7593 Manufacturer s instructions must not be taken as overriding statutory requirements Note For further information see the current issue of the Building Regulations approved document L1 in the UK and the references 1 GIL 59 2000 Central heating system specification CheSS and 2 GPG 302 2001 Controls for domestic central heating system and hot water BRECSU 1 Technical Information 9 TABLE 1 4 2000460437 3 24cxi 30cxi 38cxi N T Lift Weight 41kg 90lb 42kg 92 5lb 44kg 971b CONDENSING COAG Total Weight installed 44kg 97lb 45kg 99lb 4T7kg 103 5lb 230V 50Hz 180W Fused at 3A Gas connection 22mm copper For use on G20 20 mbar TYPE C 3 C33 Cs3 Ceg This boiler is intended exclusively EN437IP X4D Heating and return 22mm copper to be installed on a gas supply governed C 0086 Domestic hot water 15mm copper bal GB IE FAT Tir ur bar S5 E Safety valve Preset 3bar 43 5Ibf in ar aR NC
64. n of the boiler should resume when the electrical supply is restored Reset any external controls to resume normal operation of the central heating If the boiler does not resume normal operation turn the mains reset switch off and on If the boiler does not resume normal operation after this the overheat stat may have operated Overheating safety In the event of the boiler overheating the safety devices will cause a safety shutdown If this happens call your Installation Servicing company Safety Discharge Valve A safety discharge valve and discharge pipe is fitted to the boiler This valve must not be touched Should there be any discharge from the pipe isolate the boiler electrical supply and call your installer or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Frost protection The appliance has a built in frost protection device that protects the boiler from freezing With the gas and electric supplies ON and irrespective of any room thermostat setting the frost protection device will operate the pump when the temperature of the boiler water falls below 79C The burner will fire if the temperature inside the boiler falls to 39C When the temperature reaches 109C the boiler stops Any other exposed areas of the system should be protected by a separate frost thermostat Condensate Drain Blockage As a safety feature the boiler will stop working if the co
65. ndensate drain becomes blocked During freezing conditions this may be due to the forming of ice in the condense drain external to the house Release an ice blockage by the use of warm cloths on the pipe The boiler should then restart Contact your installation servicing company if the fault persists Maintenance and Servicing User Instructions Maintenance and Servicing To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage refer to guarantee registration on the inside front cover of this literature If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety Installation and Use Regulations Section 35 Servicing maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination To obtain service please call your installer or Glow worm s own Service organisation using the telephone number on the inside front cover of this literature Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be rec
66. o d pipe to discharge in a visible position outside the building facing downwards preferably over a drain The pipe must have a continuous fall and be routed to a position sothatany discharge of water possibly boiling or steam cannot create any danger to persons damage to property or external electrical components and wiring To ease future servicing it is advisable to use a compression type fitting to extend the safety discharge valve tube 8 2 Condensate Drain Connection The condensate drain connection is behind the pump atthe rear ofthe boiler see diagram 8 2 A flexible condensate outlet pipe is supplied loose in the base polystyrene packaging and should be used to fiton to the drain connection if required to discharge condensate to a drain The drain pipe should have a fall of a least 2 5 away from the boiler Condensate should if possible be discharged into the household internal drainage system If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away refer to diagram 8 3 It is recommended that any external condensate drain pipe is insulated and also preferably of 32mm diameter to prevent freezing in adverse weather conditions The condensate is discharged periodically in slugs by siphonic action It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 75mm high trap inside the boiler Fitting an extr
67. o heating demand 4 Heating System 4 6 Water Treatment Inthe case of an existing installation it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed For optimum performance after installation of a new system the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 1992 using acleanser such as Sentinel X300 or X400 Fernox restorer or Salamander corrosion guard cleaner For long term corrosion protection after flushing an inhibitor suitable for stainless steel exchangers should be used refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems Examples are Sentinel X100 Fernox protector or Salamander corrosion guard inhibitor 4 7 Draining Tap A draining tap must be provided at the lowest points of the system which will allow the entire system to be drained See addendum A drain tap for the appliance is provided as an integral part of the hydroblock see diagram 12 10 General All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations For GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide For lE The current edition of S 813 Domestic Gas Installations 12945 REDU
68. ockwise looking down until the gas pipe end is over the large hole in boiler chassis see diagram 12 5 002001 3349 02 32 12853 COMBUSTION ANALYSER TEST POINT FLUE DUCT EXTENSION Diagram 12 1 RETAINING SLOTS TORX SCREWS 3 9808 REAR PANEL gt RETAINING CORE CONTROL BOX Diagram 12 2 SPARK st z GAP 3 5 4 5 EXCHANGER GASKET SECURING SCREW 2 OFF EARTH LEAD 12 Servicing Withdraw the gas pipe from gas valve connection and remove NOTE When replacing ensure that the sealing grommet situated below the gas valve is correctly re seated Disconnect the gas valve electrical plug at the gas valve Disconnect the electrical leads from the fan Remove the five combustion chamber front retaining nuts see diagram 12 6 Gently remove the fan gas valve and burner assembly from the combustion chamber see diagram 12 4 Clean the burner with a soft brush taking great care not to damage the front insulation DO NOT use wire or sharp instruments to clean the holes of the burner Inspect the burner for any signs of damage Inspect the sealing rings and replace if necessary Removal ofthe burner is not necessary during a normal service NOTE IF THE BURNER HAS TO BE REMOVED IT WILL REQUIRE A NEW GASKET WHEN REFITTED 12 4 Combustion Chamber and Heat Exchanger Refer to diagram 12 4 Remove loose debris from
69. only or a roof and one wall require special consideration with respectto any openings doors vents or windows under the roof Care is required to protect the roof if made of plastic sheeting If the carport comprises of a roof and two or more walls seek advice from the local gas supply company before installing the boiler 3 5 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal The guard should be similar to that shown in diagram 3 6 A suitable guard is manufactured by Tower Flue Components Morley Rd Tonbridge Kent TN9 1RA Size 280mm x 280mm x 270mm TERMINAL GUARD NN ret T NNI NOY ONE LS an AS a S 1 121114 msan JAJAA TETES Id EEE ET 4E 1L 14 4 S BS SE BU WE BE WE JAJJI JI I 1 d Diagram 3 6 15 0020013349 02 4 Heating System 4 1 General The boiler is for use only with sealed central heating systems The safety valve is an integral part of the boiler and it cannot be adjusted The digital readout on the controls fascia indicates the system pressure when there is no central heating demand The circulation pump is integral with the boiler 4 2 Expansion Vessel The boile
70. or access refer to section 14 38 Disconnect the electrical connection from the 230V controls interface board and the electrical connection from the Main PCB Remove the 230V controls interface retaining screw Remove the 230V controls interface board see diagram 14 28 14 46 Condense Drain For access refer to section 14 1 Refer to diagram 14 29 Remove the clips securing the flexible tubes to the siphon adapter by twisting the clips slightly to disengage the clip jaws from each other Remove black flexible tubes from siphon adapter Lift off the siphon adapter 11417 USER INTERFACE Diagram 14 27 230V CONTROLS INTERFACE BOARD RETAINING SCREW 11419 D O e 2 USER INTERFACE Diagram 14 28 0020013349 02 50 15 Spare Parts Remove the drain connection downstream of the condense trap Remove the two condense trap securing screws Lift up and carefully remove the condense trap taking care not to spill any water which may be left in the unit As the unit is lifted remove the flexible pipe on the outlet Remove the cap at the base of the condense trap Remove any solids found Remove the float to clean it Flush water through the trap to remove any remaining solids Check for any debris in the outlet pipe of the condensate drain and clean as necessary Reassemble and refit the condense trap When refitting the cap ensur
71. orded in your benchmark Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 Spare Parts Remember when replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm Ifapartisrequired contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance this infomation will be on the name badge on the front of the appliance If in doubt seek advice from the local gas company or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet 0020013349 02 Operating the Boiler User Instructions conma DIGITAL NO PRE HEAT ECONOMY POSITION 2 LIGHT DISPLAY POSITION APPROX 55 WITH PRE HEAT 0 n CENTRAL HEATING HOT WATER TEMPERATURE WATER TEMPERATURE CONTROL APPROX 62 WITH CONTROL PRE HEAT Diagram 1 OPERATION OF THE BOILER 1 Check that all isolating valves on the boiler are open and that water flows from the hot water tap 2 Ifyou are in any doubt about the boiler being filled with water contact your installer or Glow worm s own service organisation using the telephone number on the inside front cover of this book
72. orward and out of the way Using a TORX screwdriver remove the two screws securing the plate to plate heat exchanger to the hydroblock Remove the plate to plate heat exchanger by lifting it up and over the top of the left hand hydroblock When replacing the plate to plate heat exchanger ensure that the four rubber sealing washers are fitted into the hydroblock NOTE The plate to plate heat exchanger only fits one way round TOP is marked on the plate Refill vent and pressurise the boiler Open the cold water isolation valve and slowly open a hot water tap to remove air Close the hot water tap and check for any leaks Open the heating circuit isolation valves re pressurise the system as necessary 47 RETAINING CLIP 0020013349 02 14 Replacement of Parts 14 34 Hydroblock Assembly Left Hand Refer to section 12 9 to drain the boiler heating circuit Refer to section 12 10 and drain the boiler hot water circuit Refer to diagram 14 23 Undo the connector on the bottom of the flow pipe from the hydroblock Undo the nut connecting flow pipe to heat exchanger Lift the flow pipe up out of the way Remove the filling loop tube refer to section14 25 Remove the reduced pressure zone valve refer to section 14 28 Remove the bypass tube refer to section 14 24 Undothe safety discharge valve union and remove the pipework Remove the securing clip and withdraw the safety discharge val
73. ot to allow the fascia to drop down and damage the wiring Turn on the electrical supply Ensure external controls are calling for heat The boiler should fire automatically Allow the boiler to fire for a minimum of 60 seconds and then using an electrical screwdriver rotate the service potentiometer fully clockwise see diagram 12 7 This will allow the digital display to indicate the flashing fan speed on the appliance fascia In the fully clockwise position the display should be indicating the maximum fan speed of the appliance in central heating mode this should be 39 1 for 24cxi 45 1 for 30cxi and 45 1 for 38cxi With domestic hot water max demand this should be 5121 for 24cxi 57 1 for 30cxi and 57 1 for 38cxi Check the CO value which should be 9 1 0 2 0 5 Note that with the inner casing panel fitted the combustion readings will increase slightly to 9 3 0 3 0 5 If adjustment proves necessary then proceed as follows Any adjustment to the gas valve should only be carried out by a competent person Refer to diagram 11 4 Adjust the maximum rate CO with the throttle to 9 1 Rotate anti clockwise to increase Rotate the service potentiometer fully anti clockwise Hold it in this position for about 5 seconds before rotating the service potentiometer clockwise to the mid point or 3 o clock position The fan should reduce to 1200 100 rpm which will flash 12 1 on the digital display Check the CO val
74. ove simply undo the two screws on the underside of the front panel and lift off see diagram 11 1 Undo the two screws on the front of inner panel and lift off see diagram 11 1 Unless stated otherwise any part removed during servicing should be replaced in the reverse order to removal Servicing should always include the removal of any debris from the condensate pipe and siphon After completing any servicing of gas carrying components ALWAYS test for gas soundness and carry out a functional test of the controls Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA 12 2 Spark Electrode Disconnect the electrode lead and two securing screws Withdraw the spark electrode carefully from the combustion chamber see diagram 12 3 and 12 6 Inspect the tips for damage Clean away any debris and check the spark gap is 3 5 to 4 5 mm Check the electrode gasket for signs of damage and replace if necessary 12 3 Burner Drop down the control panel into the service position see diagram 12 2 Disconnectthe gas supply atthe gas service cock see diagram 7 1 Remove the two gas pipe retaining clips one located below gas valve and the other one located on the underside of the boiler chassis see diagram 12 5 Pull sealing grommet down gas pipe see diagram 12 5 Push the gas pipe upwards further into gas valve connection and then rotate anti cl
75. pen a hot water tap The diverter valve motor will move to hot water supply and the display will read system pressure Check that hot water is available and then close the hot water tap Turn the Central heating water temperature control knob to the desired temperature The appliance will then continue to fire in central heating until the user controls are satisfied or there is another demand made for hot water NOTE After first power up the firing sequence for central heating changes After one minute stabilisation time the boiler will ramp slowly to full rate rather than going immediately to full rate This is an adaptive feature to cope with small system requirements 11 5 Testing Natural Gas ONLY Should any doubt exist about the gas rate check it using the gas meter test dial and stop watch at least 10 minutes after the burner has lit making sure that all other gas burning appliances and pilot lights are off The approximate gas rates 24cxi 2 24m h 79ft h 30cxi 2 8m h 99ft9 h 38cxi 3 6m h 127ft3 h The gas valve is factory set for natural gas G20 and should need no adjustment LPG G31 should be adjusted as described on the previous page It should be checked that the supply pressure is 20mbar when the boiler is firing at full rate This can be achieved by turning on several hot water taps and checking the inlet pressure at the inlet pressure test point on the gas valve shown in diagram 11 4 Turn taps of
76. practicable The diagrams 3 1 to 3 4 describe the lengths achievable without the use of extensions or elbows N 208 min to 413 max 59 WALL THICKNESS s OUTSIDE BOILER WALL FACE MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max TOP REAR FLUE TELESCOPIC Diagram 3 3 NOTE If necessary it is permitted to increase this dimension to 600mm max a clearance OUTSIDE INTERNAL WALLFACE SURFACE Max distance from outside Min distance from outside wall face to min clearance wall face to min clearance LH 125mm RH 153mm LH 330mm RH 358mm Diagram 3 4 TOP SIDE FLUE TELESCOPIC 0020013349 02 14 3 Flue Location and Ventilation UNDER CAR PORT etc MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION MM HORIZONTAL FLUES A DIRECTLY BELOW AN OPENING AIR BRICK OPENING WINDOWS 300 B ABOVE AN OPENING AIR BRICK OPENING WINDOWS 300 C HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS 300 D BELOW GUTTER DRAIN SOIL PIPE 25 E BELOW EAVES 25 F BELOW A BALCONY OR CAR PORT 25 G FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25 H FROM INTERNAL EXTERNAL CORNERS 25 H TO A BOUNDARY ALONGSIDE THE TERMINAL 300 ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 J FRO
77. r access refer to section 14 1 Refer to diagram 14 7 Remove circlip Remove steel washer Remove glass Remove fibre washer Replace in reverse order 14 11 Expansion Vessel For access refer to section 14 1 Refer to section 12 9 and drain the boiler heating circuit Undo the coupling at the base of the vessel see diagram 14 8 While holding the vessel remove the securing bolt on the top panel of the boiler Remove upper support bracket Lift the vessel up draw bottom outto the left lower and remove Fit the replacement unit 41 24cxi Illustrated 9 9 6D J GAS MANIFOLD NES 6 SECURING EDA SCREW 2 OSG 11487 SECURING INSULATION REW 4 0 Diagram 14 5 WASHER INSULATION SECURING SCREW HEAT EXCHANGER Diagram 14 6 0020013349 02 14 Replacement of Parts Fit a new gasket between the expansion vessel and coupling Refill vent and pressurise the boiler Check for leaks 14 12 Heat Exchanger Refer to Manual Handling section on page 5 For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Drain the boiler heating circuit see section 12 9 Drain the boiler hot water circuit see section 12 10 Remove the clip securing the clear condense pipe to heat exchanger Pull to remove the clear condense pipe out of the bottom of the
78. r has an integral expansion vessel with a capacity of 8 litres 1 76 gallons with a charge pressure of 0 5bar NOTE The expansion vessel volume depends on the total water system volume and the initial system design pressure Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 for IE refer to the current edition of 1 5 813 Domestic Gas Installations Table 3 Flow Rate MODEL MINIMUM FLOW RATE 24 cxi 774 litres hr 30 cxi 1032 litres hr 38 cxi 1289 litres hr This is equal to 209C differential at maximum heat input gt BOILER Domestic WATER Filling device a HOT OUT COLD SUPPLY IN ADDITIONAL EXPANSION VESSEL if required BYPASS if required gt lt HEATING CIRCUIT DRAIN FLOW CONTROL X POINT VALVE Refer to section 11 6 Diagram 4 1 002001 3349 02 4 3 Flow Rate If itis necessary to alter the flow rate the system can be fitted with a lockable balancing valve in the main flow or return pipes shown as valve A in diagram 4 1 The flow rate through the boiler must not be allowed to fall below that given in table 3 4 4 Bypass The boiler is fitted with an adjustable automatic bypass Ensure that under no circumstances does the flow rate drop below the figure specified refer to table 3 and section 11 6 The installation of the boiler must comply with the requirements of the current iss
79. s as below 1 Test insulation resistance to earth of mains cables 2 Test the earth continuity and short circuit of cables 3 Test the polarity of the mains RETAINING LATCHES SYSTEM CONTROLS CABLE MAINS VOLTAGE 11408 Diagram 10 3 CABLE 8 A MAINS CABLE SYSTEM CONTROLS CABLE STRAIN RELIEF Diagram 10 4 BOILER TO MAIN PCB CONTROLS CONNECTOR J15 FACE PCB CONNECTION ON CONTROLS BOX COVER S VOLTAGE REMOVE LINK EATING WHEN ANY EXTERNAL CONTROLS CONTROLS ARE USED CONNECTION PLUG 3 AMP FUSE DOUBLE POLE VV PROGRAMMER ISOLATOR 7 P le 230V ac ROOM THERMOSTAT COEM Rd 230V FROST THERMOSTAT mains suPPLY 9 Y N BOILER TO MAIN PCB coNTRoLs CONNECTOR J15 INTERFACE VOLTAGE FREE MAINS VOLTAGE REMOVE LINK HEATING WHEN ANY EXTERNAL CONTROLS CONTROLS ARE USED CONNECTION PLUG PROGRAMMER ROOM Y THERMOSTAT JUNCTION BOX OPTIONAL 3 AMP FUSE DOUBLE POLE 9 4 BUILT IN PROGRAMMER YY 230V ac ROOM THERMOSTAT 230V 50Hz PERMANENT 230V ac FROST THERMOSTAT MAINS SUPPLY Diagram 10 5 0020013349 02 28 11 Commissioning Please ensure the Benchmark logbook is completed and left with the user and the magnetic lighting instruction label is placed on the surface of the boiler casing LPG CONVERSION 3
80. s the requirements of Statutory Instrument No 3083 The Boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Typetestfor purposes of Regulation 5 certified by Notified body 0087 Product production certified by Notified body 0086 The CE mark on this appliance shows compliance with 1 Directive 90 396 EEC onthe approximation ofthe laws ofthe Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC onthe harmonisation of the Laws ofthe Member States relating to electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility 002001 3349 02 Control of Substances Hazardous to Health Under Section 6 of The Health and Safety at Work Act 1974 we are requiredto provide information on substances hazardous to health The adhesives and sealants used in this appliance are cured and give no known hazard in this state Insulation Pads Ceramic Fibre These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your h
81. ssary refer to diagram 11 4 andusing a 2mm allen key carefully adjustthe offset screw until a CO reading of 10 5 0 2 is achieved Turning the offset screw clockwise increases the CO reading 10 After setting combustion rotate the service potentiometer fully anti clockwise so that the display indicates the water temperature Check that the CO combustion remains between 9 8 and 10 8 CO Further adjustment should not be necessary however if required carefully adjust the gas valve throttle see diagram 11 4 until this is achieved 11 Remove analyser probe fromthe test point and replace the cap Refit the control panel 12 Fitthe LPG conversion label supplied in the documentation pack to the inner front panel alongside the data label Refit the inner door and outer door 11 1 Filling Domestic Water Circuit Fully open any valves in the domestic water supply to the boiler Open the domestic water isolation valve slot in line with the length of the valve see diagram 7 1 Open all hot water taps in turn and close them when water flows Check for water soundness of the complete domestic water system 29 The water flow rate is restricted to a maximum 10 l min 24cxi 12 l min 30cxi and15 5 l min 38cxi by a restrictor fitted during boiler installation see diagram 7 1 11 2 Filling the Heating Circuit Refer to section 4 to fill the system Openthe two central heating isolating valves and domestic cold water in
82. stem and any heating system controls to the electrical supply must be through a common isolator Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole The fused spur box should be readily accessible and preferably adjacent to the boiler It should be identified as to its use A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that a They are not used in a room containing a fixed bath or shower b Both the plug and socket comply with the current issue of BS1363 10 1 Mains Cable Important If a replacement supply cable is required it must be purchased Part No S1008600 10 2 Voltage Free System Controls WARNING UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG This boiler will operate continuously on heating as supplied if the wire link E fitted between the two terminals of the heating controls connection is left in place see diagram 10 1 System heating controls e g Room thermostat should be fitted in accordance with the rules in force Refer to diagram 10 2 27 10181 PANEL REAR COVER CABLE EXIT SECURING SCREW 3 VOLTAGE FREE CONTROL HEATING PANEL CONTROLS REAR WIRE CONNECTION LINK p COVER Diagram 10 1 N TO MAIN
83. ter the boiler has been mounted 9 4 Flue Attachment To Boiler Secure the flue elbow in position on top of the boiler with four torque headed screws supplied Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit the air duct then fit the collar and secure with screws provided see diagram 9 9 NOTE If the air and flue ducts have been correctly cut to the instructions given in section 9 2 the rubber sealing collar should fit flush with the outside wall check this Slide the internal trim ring back against the wall securing in place with a small amount of sealant if required 0020013349 02 12852 AIR DUCT TELESCOPIC TOP TELESCOPIC AIR DUCT SECURING Diagram 9 7 N t co CP AIR DUCT Co L 13mm TERMINAL CATCH FLUE DUCT L 11mm DUCT CUTTING LENGTHS Diagram 9 8 Sd Diagram 9 9 10 Electrical Connection WARNING This appliance must be earthed This appliance must be wired in accordance with these instructions Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB Do not interrupt the mains supply with a time switch or programmer Connection of the whole electrical sy
84. ue which should be 9 1 0 2 0 5 For Propane the CO value should be 10 5 0 3 0 7 If adjustment proves necessary then proceed as follows Adjustment of the CO at minimum rate is very coarse so carefully adjust the CO with the offset adjustment to 9 196 see diagram 11 4 Rotate the service potentiometer fully clockwise see diagram 12 7 and re check the maximum rate combustion which should be 9 196 40 2 0 5 After checking combustion rotate the service potentiometer fully anti clockwise so that the display indicates the water temperature Replace the cap on the test point and refit the control cover rear panel 002001 3349 02 RETAINING LATCHES CONTROLS FASCIA 11472 USER INTERFACE SERVICE vax POTENTIOMETER Le POTENTIOMETERS Diagram 12 7 59 5 DOMESTIC SECURING COLD WATER CLIP INLET FILTER HOUSING Diagram 12 8 12 Servicing 12 7 Domestic Cold Water Inlet Filter If the water flow rate through the appliance has reduced it may be necessary to clean or replace the water inlet filter Turn off the electrical supply to the boiler Refer to section 12 10 and drain the domestic hot water circuit Slide out the securing clip which holds the filter in its housing to the left of the pump remove the filter to clean or renew if necessary see diagram 12 8 Replace the filter into its housing and replace the securing clip Open t
85. ue of BS6798 in Ireland refer also to the current edition of 1 5 813 Domestic Gas Installations In GB it is necessary to comply with the Water Supply Water Fittings Regulations 1999 for Scotland the Water Byelaws 2000 Scotland To comply with the Water regulations your attention is drawn to The Water Regulations guide published by the Water Regulations Advisory Service WRAS gives full details of the requirements In IE the requirements given in the current edition of 1 5 813 Domestic Gas Installations andthe current Building Regulations must be followed 4 5 Filling the Sealed System NOTE The water pressure at the boiler must be at least 1 2bar to enable filling the boiler to a minimum pressure If not pressurisation must be carried out by an alternative filling loop The boiler has a built in filling device see diagram 4 2 A push on extension is supplied in the loose items pack to ease access to the filling device tap This filling device is designed to enable the re pressurisation of the system in the event of loss of pressure It is not intended to be used to completely fill the system If so used it may take a long time to fill the system To fill the system quickly provision should be made to include a proprietry filling loop external to the boiler Suitable external filling systems are shown diagramatically see diagram 4 3 The system should be pressurized to 1 bar indicated on the digital display with n
86. using legs Do not twist reposition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required 0020013349 02 Manual Handling Carriage of carton from point of delivery to point of installation first or higher floor cellar Recommend 2 person lift or 1 person with use of sack truck If 1 personis performing lift straddle the load tiltand place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do notlean forward sideways Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist reposition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation roofspace Recommend 2 person lift Ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Clear the route before attempting the lift Take
87. ve refer to section 14 16 Remove securing clips 1 and 2 below hydroblock see diagram 14 23 Undo three securing screws on the underside of the left hand hydroblock Remove the diverter valve motor as described in section 14 14 Remove left hand hydroblock from plate to plate heat exchanger using a TORX screwdriver to remove the securing screw see diagram 14 23 Lift out the left hand hydroblock Remove the remaining components for refitting into the replacement left hand hydroblock Refill vent and pressurise the boiler Open the cold water isolation valve and slowly open a hot water tap to remove air Close the hot water tap Check for any leaks 14 35 Hydroblock Assembly Right Hand For access refer to section 14 1 Refer to section 12 9 to drain the boiler heating circuit Refer to section 12 10 and drain the boiler hot water circuit Refer to diagram 14 23 Undo the connector on the bottom of the return pipe from the hydroblock Undo the nut connecting return pipe to heat exchanger Lift the return pipe up out of the way Undo the coupling at the base of the expansion vessel see diagram 14 8 Remove the clip holding the expansion vessel coupling into the top of the right hand hydroblock Move the coupling out of the way Remove pump head refer to section 14 15 NOTE It is not necessary to disconnect the electrical lead but put pump head in a convenient place where it will not strain the lead R
88. vided see diagram 2 1 Additional clearances may be beneficial around the boiler for installation and servicing For flue installations where external access is not practicable consideration should be given for the space required to insert the flue internally which may necessitate clearance larger than those specified in diagram 2 1 2 3 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 Ifin doubt seek advice fromthe local gas undertaking or Glow worm 2 4 Room Ventilation The boiler is room sealed so when it is installed in a room or space a permanent air vent is not required 2 5 Cupboard or Compartment Ventilation Due to the high efficiency and hence low casing temperature of this boiler cupboard or compartment ventilation is not necessary Leave existing air vents 13 150 COMME S 20 200 A removable compartment door can be placed at least 5mm in front of the appliance MINIMUM CLEARANCE FROM PERMANENT SURFACES Diagram 2 1 0020013349 02 3 Flue Location and Ventilation 3 1 Flue Options This boiler is suitable for concentric Horizontal and Vertical flues elevated horizontal and vertical twin all are fitted onto the top of the boiler The Glow worm Flue Options Guide available on request or through the web site describes in detail t

24-38CXI Range Installation & Service Manual Boilers - Glow-worm

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24-38CXI Range Installation &amp; Service Manual Boilers - Glow-worm

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24-38CXI Range Installation & Service Manual Boilers - Glow-worm